Hydrogel Particle Encapsulation and Suspension Media Removal

ABSTRACT

A hydrogel particle encapsulation and suspension media removal method includes combining hydrogel materials, which include a hydrogel polymer, a linker, a cargo suspension, and a suspension media. The hydrogel materials are mixed to form a hydrogel-suspension media mixture. The mixed hydrogel materials are polymerized to form hydrogel particles having encapsulated cargo. The suspension media is substantially removed from the hydrogel-suspension media mixture by: adding a density adjusting material, forming a three-phase solution that includes the density adjusting material settled between the hydrogel particles and the suspension media, centrifuging the three-phase solution, agitating the three-phase solution, centrifuging the three-phase solution, and retrieving the hydrogel particles lacking the suspension media.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. ProvisionalPatent Application No. 63/390,501 entitled Particle Encapsulation andSuspension Media Removal and filed on Jul. 19, 2022, the disclosure ofwhich is herein incorporated by reference in its entirety.

BACKGROUND 1. Field

Embodiments of the invention relate to hydrogel particle productionmethods. More specifically, embodiments of the invention relate toremoval of suspension media from hydrogel particles.

2. Related Art

A variety of hydrogel particle production methods are known. Forexample, U.S. Patent Application Publication No. 2007/0134209 to Oakeydiscloses methods for producing a cellular matrix for tissueself-assembly in which living cells are encapsulated in a primaryencapsulant followed by encapsulation in a secondary encapsulant that ispolymerized. U.S. Patent Application Publication No. 2017/0145169 toOakey et al. discloses methods of using microfluidics for theoxygen-controlled generation of microparticles and hydrogels forbiological applications.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter. Other aspectsand advantages of the invention will be apparent from the followingdetailed description of the embodiments and the accompanying drawingfigures.

In an embodiment, a hydrogel particle encapsulation and suspension mediaremoval method includes: combining hydrogel materials, the hydrogelmaterials including a hydrogel polymer, a linker, a cargo suspension,and a suspension media; mixing the hydrogel materials to form ahydrogel-suspension media mixture; polymerizing the hydrogel materialsto form hydrogel particles having encapsulated cargo; and substantiallyremoving the suspension media from the hydrogel-suspension mediamixture, including: adding a density adjusting material; forming athree-phase solution, wherein the three-phase solution includes thedensity adjusting material settled between the hydrogel particles andthe suspension media; centrifuging the three-phase solution; agitatingthe three-phase solution; and retrieving the hydrogel particles lackingthe suspension media.

In another embodiment, a method for generating and purifying hydrogelparticles including encapsulated cargo includes: combining hydrogelmaterials in a container, the hydrogel materials including a hydrogelpolymer, a linker, a cargo suspension, and a suspension media; mixingthe hydrogel materials to form a hydrogel-suspension media mixture,wherein mixing includes shaking the container until the hydrogelmaterials are substantially mixed; polymerizing the hydrogel materialsto form hydrogel particles having encapsulated cargo; and substantiallyremoving the suspension media from the hydrogel-suspension mediamixture, including: adding a density adjusting material; centrifugingthe hydrogel-suspension media mixture with the density adjustingmaterial and cargo-compatible solution to form a three-phase solutioncomprising: 1) an upper phase comprising the hydrogel particlessuspended within the cargo-compatible solution, 2) a middle phasecomprising the density adjusting material, and 3) a lower phasecomprising the suspension media.

In yet another embodiment, a hydrogel particle encapsulation andsuspension media removal method includes: combining hydrogel materialsin a vial via an automated liquid handling system, the hydrogelmaterials including a hydrogel polymer, a linker, a cargo suspension,and a suspension media; transferring the vial to a shaking device via arobotic arm; mixing the hydrogel materials via the shaking device toform a hydrogel-suspension media mixture; transferring the vial from theshaking device to a UV light source via a robotic arm; polymerizing thehydrogel materials via the UV light source to form hydrogel particleshaving encapsulated cargo; and substantially removing the suspensionmedia from the hydrogel-suspension media mixture via the robotic arm andthe automated liquid handling system, including: adding a densityadjusting material to the vial; adding a cargo-compatible solution tothe vial, wherein the cargo-compatible solution comprises acargo-compatible surfactant; centrifuging the vial; forming athree-phase solution, wherein the three-phase solution includes thedensity adjusting material settled between the suspension media andcargo-compatible solution containing the hydrogel particles; agitatingthe three-phase solution via an automated mechanical mixing device;centrifuging the vial; and retrieving the hydrogel particles lacking thesuspension media.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the invention are described in detail below withreference to the attached drawing figures, wherein:

FIG. 1 depicts some embodiments of a hydrogel particle encapsulation andsuspension media removal method for generating and purifying hydrogelparticles having encapsulated cargo;

FIG. 2 depicts some embodiments of a method for removing suspensionmedia from a hydrogel-suspension media mixture;

FIG. 3 is a graph showing the effects of the number of vertical shakeson the size distribution of hydrogel particles, in some embodiments;

FIG. 4 is a graph showing the weight of recovered hydrogel particlesusing prior art methods compared to some embodiments of methodsdisclosed herein; and

FIG. 5 is a graph showing viability of hydrogel cargo using prior artmethods compared to some embodiments of methods disclosed herein.

The drawing figures do not limit the invention to the specificembodiments disclosed and described herein. The drawings are notnecessarily to scale, emphasis instead being placed upon clearlyillustrating the principles of the invention.

DETAILED DESCRIPTION

The subject matter of the invention is described in detail below to meetstatutory requirements; however, the description itself is not intendedto limit the scope of claims. Rather, the claimed subject matter mightbe embodied in other ways to include different steps or combinations ofsteps similar to the ones described in this document, in conjunctionwith other present or future technologies. Minor variations from thedescription below will be understood by one skilled in the art and areintended to be captured within the scope of the claimed invention. Termsshould not be interpreted as implying any particular ordering of varioussteps described unless the order of individual steps is explicitlydescribed.

The following detailed description references the accompanying drawingsthat illustrate specific embodiments in which the invention can bepracticed. The embodiments are intended to describe aspects of theinvention in sufficient detail to enable those skilled in the art topractice the invention. Other embodiments can be utilized and changescan be made without departing from the scope of the invention. Thefollowing detailed description is, therefore, not to be taken in alimiting sense. The scope of the invention is defined only by theappended claims, along with the full scope of the equivalents to whichsuch claims are entitled.

In this description, references to “one embodiment,” “an embodiment,” or“embodiments” mean that the feature or features being referred to areincluded in at least one embodiment of the technology. Separatereferences to “one embodiment,” “an embodiment,” or “embodiments” inthis description do not necessarily refer to the same embodiment and arealso not mutually exclusive unless so stated and/or except as will bereadily apparent to those skilled in the art from the description. Forexample, a feature, structure, act, etc. described in one embodiment mayalso be included in other embodiments, but is not necessarily included.Thus, the technology can include a variety of combinations and/orintegrations of the embodiments described herein.

Fabrication of hydrogel particles is widely applicable to a variety ofindustries and applications, including drug delivery and tissueregeneration. Fabrication of such hydrogel particles is typicallyachieved via dual phase systems, such as oil-water. Particles are formedby methods such as emulsification or microfluidic generation, resultingin an aqueous hydrogel particle suspended in a hydrophobic suspensionmedia phase. Particles must subsequently be separated from thesuspension media phase before use, as typical applications require arelatively suspension media-free environment for proper functioning ofthe cargo encapsulated therein. The suspension media removal processpresents a number of challenges. For example, in applications such aslive cell encapsulation, fast and gentle removal of the suspensionmedia, or other substances, is paramount to endpoint viability.Similarly, in other examples, fast and gentle removal of the suspensionmedia is required to maintain integrity and downstream efficacy oftherapeutic particles such as drugs, RNA, DNA, proteins, viral packages,lipid encapsulated therapies, etc. In these cases, the in vivo potencyof encapsulated material is paramount to desired therapeutic outcomesbut is compromised due to current processing methods. As such, asignificant problem in particle or cell encapsulation processes andmethods is maintaining cell viability and/or cargo integrity during thesuspension media removal process, without compromising the efficacy ofsaid removal process and resulting end product purity.

Typically, removal of the suspension media from such mixtures requiresextensive washing with high velocity centrifugation or aggressivedetergents to completely remove the suspension media. These processescan be both time consuming and deleterious to any encapsulated cargo.For example, high velocity centrifugation to remove the suspension mediadries out the cargo, adversely affecting the integrity and/or viabilityof the cargo contained within the encapsulation matrix.

Embodiments of the invention solve the above-mentioned problems byproviding a method for removing suspension media from hydrogelencapsulated cargo. This process uses a density adjusting media tocreate a protective barrier phase between the suspension media and thehydrogel encapsulated cargo during and after centrifugation. Thisprocess improves speed and efficiency of separation through dispersal ofsuspension media-aggregated particles and enables the hydrogel particlesto be centrifuged at sufficient speeds and durations to completelyremove the suspension media from the hydrogel-suspension media mixturefor improved end product purity without drying out, damaging, orotherwise impacting the encapsulated cargo. The cargo viability, processspeed and efficiency, and end product purity afforded by this processenables production of hydrogel encapsulated cargo (e.g., therapeuticcells) at sufficient quantities, purity, and therapeutic activities forhigh in vivo potency. Therapies relying on in vivo potency ofencapsulated cargo such as living cell encapsulation for treatment ofinjuries and diseases are particularly benefited. A specific example ofthis is the encapsulation of mesenchymal stem cells for treatment ofjoint, tendon, and ligament pathologies; where previous methods couldnot elicit desired therapeutic outcomes in a commercially relevantmanner due to insufficient encapsulated cell viability and/or endproduct purity at needed production scales.

Context and Concepts of the Invention

In general, the terms and phrases used herein have their art-recognizedmeaning, which can be found by reference to standard texts, journalreferences, and contexts known to those skilled in the art. Thefollowing definitions are provided to clarify their specific use in thecontext of the invention.

As used herein, the term “cargo” refers to any article to beencapsulated within a scaffold. In embodiments of the presentdisclosure, this scaffold may be a hydrogel or hydrogel particles, asdescribed in greater detail below. As non-limiting examples, cargo mayrefer to drugs, cells, exosomes, tissues, RNA, DNA, protein, viralvectors, lipid encapsulates, cell signaling factors, cellularscaffolding, caged nanoparticles, or others. In some embodiments, thecargo may be used for downstream therapeutic purposes. For example,cells such as mesenchymal stem cells, chondrocytes, osteoblasts,pancreatic islet cells, beta cells, neural cells, fibroblasts, vascularsmooth muscle cells, pluripotent stem cells, or endothelial cells may beencapsulated in the scaffold (e.g., hydrogel particles). Collections ofcells and cell products such as spheroids, organoids, and tissues mayalso be encapsulated. Any of the aforementioned examples may be appliedto a patient for therapeutic purposes. As will be discussed in greaterdetail below, the viability and/or integrity of the cargo following theencapsulation process is essential for downstream uses.

As used herein, the term “polymer” refers to a molecule composed ofrepeating structural units connected by covalent chemical bonds oftencharacterized by a substantial number of repeating units (e.g., equal toor greater than 3 repeating units, optionally, in some embodiments equalto or greater than 10 repeating units, in some embodiments, greater orequal to 30 repeating units) and a high molecular weight (e.g., greaterthan or equal to 1 kDa, in some embodiments greater than or equal to 10kDa, in some embodiments greater than or equal to 20 kDa, in someembodiments greater than or equal to 50 kDa or in some embodimentsgreater than or equal to 100 kDa). Polymers are commonly thepolymerization product of one or more monomer or macromer precursors.The term polymer includes homopolymers, or polymers consistingessentially of a single repeating monomer subunit. The term polymer alsoincludes copolymers which are formed when two or more different types ofmonomers are linked in the same polymer. Useful polymers include organicpolymers or inorganic polymers that may comprise amorphous,semi-amorphous, crystalline, or semi-crystalline states.

As used herein, the term “monomer” and/or “macromer” refer to a reagentwhich can undergo polymerization under appropriate conditions. A monomeror macromer reagent comprises at least one monomer or macromer molecule,where a monomer or macromer molecule is a molecule which can undergopolymerization, thereby contributing constitutional units to thestructure of a polymer or oligomer. In embodiments, a monomer ormacromer reagent may be represented by an average or dominant chemicalstructure and comprise monomer molecules having that chemical structure,but may also contain components with other chemical structures. Forexample, a monomer or macromer reagent may comprise impurities havingchemical structures other than the average or dominant structure of thereagent. Macromer may refer to a reagent which is polymeric, e.g., has anumber of repeating units but may further undergo polymerization to forma polymer of macromer repeating units. In some embodiments, macromerrefers to reagents having a high molecular weight (e.g., greater than orequal to 200 Da, in some embodiments greater than or equal to 1000 Da,or in some embodiments greater than or equal to 10,000 Da).

As used herein, the term “hydrogel” refers to an at least partiallyhydrophilic substance being characterized by high water absorbency. Inembodiments, hydrogel comprises an at least partially hydrophilicpolymer, superabsorbent polymer, or biomacromolecule, for example in anetwork configuration. Hydrogels may be characterized as a water swollenbut insoluble or partially insoluble substance. In some embodiments,hydrogels may absorb water greater than or equal to 10 times thehydrogel weight, greater than or equal to 50 times the hydrogel weight,or, optionally, greater than or equal to 100 times the hydrogel weight.

As used herein, the term “microparticles” or “hydrogel particles” refersto particles including polymers, having relatively small dimensionsincluding diameter, radius, height, width, depth, etc. In someembodiments, for example, microparticles or hydrogel particles refer toparticles having a lateral dimension (e.g., diameter) of less than orequal to 1 mm. In some embodiments, microparticles or hydrogel particlesrefer to particles having an average or mean diameter of less than orequal to 500 μm, less than or equal to 100 μm, or less than or equal to50 μm. In some embodiments, microparticles refer to particles havinglateral dimensions selected from the range of 10 nm to 1000 μm. In someembodiments, microparticles are microspheres. References to“microparticles” or “hydrogel particles” disclosed herein may refer tomicroparticles or hydrogel particles, respectively, that include orexclude encapsulated cargo. Said another way, reference to“microparticles” or “hydrogel particles” may or may not includeencapsulated cargo, and need not explicitly state so.

As used herein, the term “click chemistry” refers to biocompatible smallmolecule reactions used in bioconjugation that allows the joining ofsubstrates with specific biomolecules. For example, click chemistry mayrefer to chemical reactions that quickly and irreversibly react, forminga high yield of a single reaction product with high reactionspecificity. Click chemistry reactions, as used herein, may beparticularly beneficial for the formation of hydrogel particles.

As used herein, the term “density adjusting media” refers to a mediahaving a density within a predetermined range. For example, the densityof the density adjusting media may be between the density of suspensionmedia and the density of the hydrogel solution. As will be discussed ingreater detail below, in some embodiments the density adjusting mediamay be a liquid having a density of between about 1.0 g/mL to about 2.0g/mL. In some embodiments, the density adjusting media may be a liquidhaving a density of between about 1.1 g/mL to about 1.5 g/mL. In someembodiments, the density adjusting media may be a liquid having adensity of about 1.3 g/mL. In some embodiments, the density adjustingmedia is cytocompatible. As further described below, the densityadjusting media may be used to assist with physically separatingsuspension media from hydrogel.

Polyethylene glycol (PEG)-based polymers are regarded for their robustmechanical properties, elasticity, and biocompatibility. PEG polymersare easily modified with reactive groups, an example being PEGnorbornenes (PEGNB), which uses dithiolated PEG as a linear crosslinkerto facilitate the stepwise linking of thiol and ene (Thiol-Ene) unitsvia a radical mediated reaction. Compared to other synthetic monomers,PEG hydrogels using Thiol-Ene mediated crosslinking reactions arebeneficial due to their biocompatibility and chemical versatility,proceeding via simple “click” chemistry, and allowing modification witha range of monofunctional or multifunctional moieties. Such clickchemistry reactions are widely used in industrial applications includingpharmaceutical synthesis, material coatings, and nanotechnology. Basedon these characteristics, a class of photopolymerizable PEG-basedhydrogels has been developed around click chemical reactions.

Photopolymerization is a convenient and cytocompatible alternative tosolvent-based or thermal curing, and can be carried out both in-vitroand in-vivo. The photoinitiated free radical polymerization of PEGs orother suitable monomer or macromer modified with click reactivefunctional groups is typically performed in the presence of aphotoactive initiator that generates free radicals upon exposure toultraviolet light. Whereas some free radical polymerization is stronglyinhibited by oxygen (e.g., Acrylate reactions), click reactions, such asbetween thiol and vinyl groups, are not strongly oxygen inhibited, andactively consume reactive oxygen species. This is advantageous whenengineering microscale structures where the inhibition ofphotopolymerization reactions is exacerbated due to increasedsurface-to-volume ratios.

PEGNB is attractive to use as a cell encapsulant and tissue scaffoldbecause of its tissue-like physical properties, which can be tailored toclosely mimic extracellular matrices, cytocompatibility, and syntheticversatility. Over a certain polymer composition range, highlywater-swollen PEGNB hydrogel networks have been proven to becytocompatible encapsulants for many cell types. Synthetic customizationof PEGNB macromolecular architecture and chemistry provides a largediversity of properties, making it an attractive alternative to naturalhydrogels. PEGNB hydrogel networks can be decorated with cell-adhesivepeptide groups (e.g., cysteine-arginine-glycine-asparagine-serine(CRGDS)) that allow the formation of bioactive hydrogels that promotecell adhesion, spreading, and tissue elaboration. Modifications to thePEG crosslinker can provide an ability to spatially and temporallyremodel the hydrogel by hydrolytic, proteolytic, or optical degradation.Directed network remodeling has become widely used as a strategy fortemporally regulating hydrogel properties.

Microscale hydrogel particles, or “microgels” are of emerging importanceto the sensing, drug, and tissue engineering communities due tointraparticle diffusion, facile antibody or oligonucleotide conjugation,and potential for in vivo applications. PEG microgels have typicallybeen fabricated via stop-flow lithography, a single-phase microfluidicstepwise photopolymerization technique, or via microfluidic emulsion,involving forming droplets in a continuous suspension media phase atintersecting microfluidic channels or coaxial capillaries. However,microfluidic processes to produce these PEG microgels may not besufficient to achieve therapeutically relevant cargo-to-droplet ratios.For example, when the cargo to be encapsulated are cells having a radiusof between about 100 μm to about 500 μm, a therapeutically relevantratio may be any ratio above 3 cells per particle. Such ratios aredifficult to achieve via microfluidic production due to cell clumpingwithin the microfluidic device. At such high titers, cells are morelikely to interact and stick together due to proteins expressed at thecellular membrane, released signaling molecules and peptides, or otherreasons. Alternatively, PEG microspheres may be fabricated at higherrates than stop-flow lithography by emulsifying two-phase oil-watersuspensions. Furthermore, microsphere fabrication via emulsification, asdescribed, foregoes the requirement of complex, expensive instruments,thereby reducing costs associated with production and potentialbreakdown/maintenance of the complex instruments. Microparticles may beprepared by bulk aqueous phase emulsification via sonication, vortexing,or homogenization. It is noted that a common problem with sonicating,vortexing, or homogenizing is significant polydispersity of theparticles. Such polydispersity forms particles that are too small tocontain certain cargo, such as cells, which significantly decreases theencapsulation efficiency to levels below therapeutic relevance (e.g.,less than 3 cells per particle having a diameter of between about 100 μmto about 500 μm). Following emulsification, stabilized particlessuspended within the suspension media (e.g., immiscible oil) arephotopolymerized by near ultraviolet (UV) irradiation. For downstreamapplications and efficacy of the cargo, the suspension media must thenbe thoroughly removed from the hydrogel. The suspension media removalstep of prior technologies has prevented scaling and widespread use ofthe bulk two-phase oil-water suspensions. For example, one priortechnique uses high-speed centrifugation of the product to “pull-down”the suspension media from the mixture. This immediately dehydrates theencapsulated cargo, thereby negatively impacting the integrity/efficacyof the encapsulated cargo. Prior techniques have attempted to workaround this problem in a number of ways. For example, some priortechniques attempt to remove suspension media from thehydrogel-suspension media mixture by using many (e.g., seven or more)washing steps, which typically involve pipetting the mixture up and downin between low-speed centrifugation steps (e.g., about 150 relativecentrifugal force (rcf)), at which speed is not sufficient to remove allof suspension media. This process has many downsides, including: a)significantly increasing the time necessary for the separation process,effects of which include deleteriously impacting encapsulated cargo(e.g. cell viability), production throughput, and production expense; b)decreasing the overall yield of viable cargo encapsulated particles dueto particles sticking together—a result of hydrophobic interactionbetween suspension media covered particles, c) sticking of the particlesto certain components used during the multiple washing steps; d) lowthroughput process since all the particles must be delicately handwashed; e) high levels of impurities in the end product due to lowcentrifugation speeds (e.g., less than about 150 rcf) or insufficientcentrifugal times (e.g., less than 1 minute) required to not dehydrateand/or damage the cargo; and f) failure to fully remove suspension mediafrom the hydrogel also due to low centrifugation speeds (e.g., fullremoval of suspension media from the particles requires centrifugationspeeds of about 700 rcf or greater or of lower centrifugation speeds,e.g., less that 700 rcf, for at least one minute). These downsides, bothin whole and in part, prevent current methods from producingencapsulated cargo in sufficient quantity, of sufficient quality, and ofsufficient purity for many target uses (e.g. production via Current GoodManufacturing Practices (CGMP) and regulatory approval for in vivoadministration in a commercial capacity).

Hydrogel Particle Production and Purification

With reference now to FIG. 1 , an exemplary hydrogel particleencapsulation and suspension media removal method 100 for generating andpurifying hydrogel particles is shown. Descriptions of some steps ofmethod 100 will be discussed in greater detail below with reference tothe corresponding figures.

In a step 110, hydrogel materials are combined. In an example of step110, a hydrogel polymer, a linker, a cargo suspension, a suspensionmedia, and a surfactant are combined to generate the hydrogel mixture.As will be discussed below, in some embodiments a photoinitiator may beadded to aid in photopolymerization. In some embodiments, one or more ofthe aforementioned components may be mixed with one another prior togenerating the final hydrogel mixture. For example, the hydrogel polymer(e.g., 10% by weight), the linker (e.g., 10 millimol linker), thephotoinitiator (e.g., 0.1% by weight), and the cargo suspension may bemixed together to form a first mixture, and separately the suspensionmedia and the surfactant may be mixed to form a second mixture (e.g., atabout 2% surfactant). The first mixture and the second mixture may thenbe combined to generate the hydrogel mixture.

In some embodiments, the ratio of the first mixture to the secondmixture may be 1:1 to about 1:10. In some embodiments, the ratio of thefirst mixture to the second mixture may be between about 1:1 to about1:5. In some embodiments, the ratio of the first mixture to the secondmixture may be about 1:3.

In some embodiments, the second mixture may comprise a suspension mediahaving between about 0.001% to about 1% surfactant. In some embodiments,the second mixture may comprise a suspension media having between about1% to about 5% surfactant. In some embodiments, the surfactant may beanionic, cationic, or zwitterionic. In some embodiments, the surfactantmay be a non-ionic surfactant (e.g., ethoxylates, fatty alcoholethoxylates, alkylphenol ethoxylates, fatty acid ethoxylates,ethoxylated amines, fatty acid amides, fatty acid esters of polyhydroxycompounds, fatty acid esters of glycerol, fatty acid esters of sorbitol,fatty acid esters of sucrose, alkyl polyglucosides, etc.).

The suspension media used is configured to not damage the cargo. Inembodiments, the suspension media is hydrophobic to serve as ahydrophobic suspension media for hydrophilic material such as hydrogelmaterial. In some embodiments, the suspension media used may allow foroxygen delivery/consumption by the cargo (e.g., in the case that thecargo comprises viable cells). In some embodiments, the suspension mediamay be an oil such as NOVEC™ 7500 oil (3M™), halocarbon oil, mineraloil, or similar; further, a fluorinated version of these oils, or otherengineered hydrophobic fluid suitable for creating two phase suspensionsmay be used. For example, a fluorosurfactant such as RAN008-FluoroSurfactant (RAN Biotechnologies, Beverly, MA) may be mixedwith the oil to provide a final concentration of 0.02% to 2%fluorosurfactant. In certain embodiments, the RAN 008-FluoroSurfactantis mixed with NOVEC™ 7500 oil with a final concentration of 2%.

In some embodiments, the hydrogel polymer may be any one or combinationof hyaluronic acid, cartilage, gelatin, chitosan, heparin, alginate,fibrin, polyvinyl alcohol, PEG, sodium polyacrylate, or similar. In someembodiments, the hydrogel polymer may be functionalized with reactivegroups such as acrylate, methacrylate, thiol, tetrazine, azide,aminooxy, etc. In some embodiments, the hydrogel polymer may be any oneor combination of PEG-based polymers, such as PEG, PEG diacrylate(PEGDA), PEG Norbornene (PEGNB), PEG maleimide, PEG cyclooctyne, PEGtriarylphosphine or PEG disulfide. In some embodiments, the hydrogelpolymer may be of a specific weight. For example, the hydrogel polymermay be between about 250 Da to about 20 kDa. In some embodiments, thehydrogel polymer may be between about 20 kDa to about 250 kDa. In someembodiments, PEG groups may possess various geometries includingBranched PEGs, Star PEGs or Comb PEGs.

In some embodiments, the linker may be any one or combination of thiol,acetylene, vinyl Sulphone, azide, amine, acid, methyl Ether, Diol,tetrazine, aminooxy, etc.

In some embodiments, the photoinitiator may be any compound thatcatalyzes the crosslinking and polymerization of the hydrogel. Forexample, the photoinitiator may be any one or combination of lithiumphenyl-2,4,6-trimethylbenzoylphosphiante (LAP), or vitamin B2 combinedwith triethanolamine (B2/TEOA), 2-dimethoy-2-phenylacetophenone (DMPA),2-hydroxy-4-(2-hydroxyethoxy)-2-methylpropiophenone (12959). In someembodiments, LAP may be advantageous for this process. LAP enablesefficient photopolymerization around near visible spectra of UV light,thereby avoiding DNA damage associated with UV and far UV spectrum.

As mentioned above, the cargo suspension may have cargo including anyone or combination of the following: drugs, cells, viable cells (e.g.,mammalian cells), RNA, DNA, protein, viral vectors, lipid encapsulates,cell signaling factors (e.g., exosomes), cellular scaffolding, cagednanoparticles, or others.

In a step 120, the hydrogel mixture is mixed. In an example of step 120,mixing the hydrogel materials comprises: 1) accelerating a containerholding combined hydrogel materials in a first direction, 2)decelerating the container to a stop, 3) accelerating the container in asecond (opposite) direction back to an initial position, and 4)repeating steps 1-3 a plurality of times. For example, the hydrogelmaterials may be mixed via shaking a tube containing the hydrogelmixture by hand, or via a shaking device, in a vertical up and downmotion. An exemplary shaking device is a Liquid Shaker gelvarnish/polish shaking machine (foreverLily), which has a shaking motiondistance of about ¾-inch and is used with tubes from 1.5 to 5 mL. Largertubes (e.g., 100 mL) may be used with shaking by hand or a largershaking device. A speed of the shaking device may be adjustable (e.g.,from one shake per second to six shakes per second). In certainembodiments, the speed is set to four shakes per second and the shakingduration is approximately one second. Importantly, the number ofvertical shaking steps can be used to effect the size of the resultinghydrogel particles. For example, as illustrated in FIG. 3 , followingthree vertical shakes roughly 28% of the hydrogel particles are about100 μm and roughly 10% of the hydrogel particles are about 400 μm. Inanother example, following five vertical shakes roughly 37% of thehydrogel particles are about 100 μm and roughly 5% of the hydrogelparticles are about 400 μm. In another example, following 7 verticalshakes roughly 48% of the hydrogel particles are about 100 μm androughly 2% of the hydrogel particles are about 400 μm.

Also importantly, as mentioned above, mechanical agitation (e.g.,vortexing, sonicating, and/or homogenizing) of the hydrogel materials ina non-vertical shaking manner, may lead to polydispersity, decreasingthe size of a portion of the hydrogel particles such that 3 or fewercells/cargo are able to be combined. Accordingly, in some embodimentsthe shaking of the hydrogel materials is performed with between about0.5 Newtons to about 5000 Newtons of force, determined using anaccelerometer, to form hydrogel particles that are between about 80 μmto about 500 μm.

In a step 130, the hydrogel is polymerized. In an example of step 130,the hydrogel mixture is photopolymerized using a light source. Forexample, the hydrogel mixture may be exposed to UV light or near UVlight at a specific wavelength, a specific energy, and a specific timeto cause polymerization of the hydrogel polymers contained within. Insome embodiments, the wavelength of the UV light may be between about365 nm to about 435 nm. In some embodiments, the energy of the UV lightmay be between about 1 mW/cm² to about 200 mW/cm². In some embodiments,the energy of the UV light may be between about 50 mW/cm² to about 150mW/cm². In some embodiments, the energy of the UV light may be about 100mW/cm². In some embodiments, the hydrogel mixture may be exposed to UVlight for a period of between about 0.1 seconds to about 40 seconds. Insome embodiments, the hydrogel mixture may be exposed to UV light for aperiod of between about 1 second to about 30 seconds. In someembodiments, the hydrogel mixture may be exposed to UV light for aperiod of about 20 seconds.

Importantly, the wavelength, intensity, and duration of the UV lightexposure heavily affects the polymerization of the hydrogel material.For example, if the hydrogel mixture is exposed for too long a durationor at too high of an intensity, then the hydrogel material may becometoo heavily polymerized and prevent downstream resuspension of thehydrogel particles. Alternatively, if the hydrogel material is exposedfor too short a duration or at too low of an intensity, then thehydrogel material will not be sufficiently polymerized to properlyencapsulate the cargo within.

In some embodiments, methods other than photopolymerization may be usedto induce polymerization of the hydrogel. For example, temperature,radiation, electricity, chemical, enzymatic, or other means for inducingpolymerization may each be alternatively used at step 130 to causepolymerization of the hydrogel. In some embodiments, wavelengths otherthan the UV spectrum may be used for photopolymerization. In someembodiments infrared (IR) light may be used. For example, wavelengths ofbetween about 700 nm to about 1 mm may be used for photopolymerization.

In a step 140, suspension media is removed from the hydrogel mixture forpurifying the hydrogel particles from the suspension media. Withreference to FIG. 2 , step 140 is shown in some embodiments as a processhaving multiple sub-steps.

In a step 141, a density adjusting material is added to thehydrogel-suspension media mixture. The density adjusting material may bean aqueous solution configured to separate the hydrogel solution fromthe suspension media (e.g., by forming a three-phase layered solutionhaving the density adjusting material located in the middle phase). Inan example of step 141, a density adjusting material is added to thehydrogel-suspension media mixture at a ratio of 1:2 (1 part densityadjusting material to 2 parts hydrogel-suspension media mixture). Insome embodiments, the density adjusting material is added to thehydrogel-suspension media mixture at a ratio between about 1:0.5 toabout 1:5.

The density adjusting material is configured to be a certain density toallow for separation of the suspension media from the hydrogel solutionbased on density differences therebetween. For example, in someembodiments the density adjusting material is between about 1.1 g/mL toabout 1.6 g/mL. In some embodiments, the density adjusting material isbetween about 1.2 g/mL to about 1.4 g/mL. In some embodiments, thedensity adjusting material is about 1.3 g/mL. In some embodiments, thedensity of the density adjusting material may be adjusted according tothe density of the suspension media used. For example, if a suspensionmedia is used at a density of 2.5 g/mL, then the density adjustingmaterial may have a density greater than the density of themicroparticle density but less than the density of the suspension media,which in this example would be less than 2.5 g/mL.

In some embodiments, different solutions having the above densities maybe used as the density adjusting material. For example, the densityadjusting material may be any one or combination of optiprep oriodixanol. It is further contemplated that the density adjustingmaterial is compatible with the encapsulated cargo, and certainsolutions may be chosen based on the encapsulated cargo. It iscontemplated the density adjusting material may have one or a number ofsurfactants added, suitable for furthering the removal of suspensionmedia from particles.

In a step 142, a cargo-compatible solution is added. In an example ofstep 142, a cargo-compatible solution containing a cargo-compatiblesurfactant is added to the mixture. In some embodiments, thecargo-compatible solution is added at a ratio between about 1:0.5 toabout 1:4 (1 part cargo-compatible solution to 4 parts hydrogelmixture+density adjusting material). The cargo-compatible surfactant mayaid in the separation of the suspension media from the hydrogelmaterial. In some embodiments, the cargo-compatible surfactant may beanionic, cationic, or zwitterionic. In some embodiments, thecargo-compatible surfactant may be a non-ionic surfactant (e.g.,ethoxylates, fatty alcohol ethoxylates, alkylphenol ethoxylates, fattyacid ethoxylates, ethoxylated amines, fatty acid amides, fatty acidesters of polyhydroxy compounds, fatty acid esters of glycerol, fattyacid esters of sorbitol, fatty acid esters of sucrose, alkylpolyglucosides, etc.). In some embodiments, the cargo-compatiblesolution includes any one or combination of Dulbecco's Modified EagleMedium (DMEM), Fetal Bovine Serum (FBS), Penicillin, Streptomycin,phosphate-buffered saline (PBS), Normal Saline, Lactated Ringers, or anyother biocompatible or drug relevant solution.

In a step 143, a three-phase solution is formed. In an example of step143, the mixture is centrifuged to form a three-phase solution asdescribed below. In some embodiments, the mixture may be centrifuged fora period of between about 30 seconds to about 10 minutes. In someembodiments, the mixture may be centrifuged for a period of betweenabout 30 seconds to about 5 minutes. In some embodiments, the mixturemay be centrifuged at a force of between about 200 rcf to about 900 rcf.In certain embodiments, the mixture may be centrifuged for 3 minutes ata force of 350 rcf.

The three-phase solution has an upper phase being the aqueous phasecontaining hydrogel, a middle phase being the density adjusting materialphase, and a bottom phase being the suspension media phase. Such athree-phase distribution provides a physical barrier (i.e., the middlephase) between suspension media (i.e., lower phase) and the aqueous(i.e., upper phase) which assists with facile separation of thesuspension media from the hydrogel. During experimental procedures,formation of the three-phase solution was unexpected because thehydrogel material was anticipated to partially or fully form a misciblemixture with the density adjusting material during centrifugation due toboth being hydrophilic. For example, some embodiments of the densityadjusting material (e.g., optiprep) were expected to form a misciblemixture with the hydrogel material due to both being hydrophilic despitetheir differences in density. Accordingly, a three-phase solutionfollowing the addition of the density adjusting material was unexpected.During and following the forced separation achieved by centrifugation,the three-phase solution persists for minutes to hours, which is used toseparate the suspension media from the hydrogel material. Such aseparation of phases, with the middle phase settling between thesuspension media and the aqueous hydrogel containing phase, improvespurification of the hydrogel particles from the suspension media, whilepreventing the cargo (e.g., cells) from drying out, which is criticalfor maintaining viability of the cargo and thereby its biologicactivity. Distribution of the hydrogel at the bottom of the upperaqueous phase prevents the cargo from being exposed to air.

In a step 144, the mixture is mechanically agitated. In an example ofstep 144, the mixture is mechanically agitated with a mechanical mixingdevice (e.g., a Scientific Industries GENIE G560 Vortex-Genie 2) using aforce of about 1 Newton per 300 μl of particles about 20 times todislodge the hydrogel/suspension media clump. For example,hydrogel/suspension media clumps are portions of hydrogel particles thatare partially held together due to trapped suspension media heldtherebetween. The trapped suspension media not only causes the hydrogelparticles to stick to one another, but the clumps may also stick to theside of the container. To sufficiently remove the suspension media fromthe hydrogel particles, the hydrogel/suspension media clumps may need tobe dislodged from the side of the container. Accordingly, a clear orsubstantially transparent container may be used to visually inspect forhydrogel/suspension media clumps. In some embodiments, a force ofbetween about 0.5 Newtons to about 5000 Newtons is used to dislodge thehydrogel/suspension media clumps. In some embodiments, the mechanicalagitation may be performed between about 3 times to about 40 times.Since step 144 is performed after the cargo has been encapsulated in theappropriately sized hydrogel particles in steps 130 and 140, mechanicalagitation may be used at this step without affecting the size of theparticles and the amount of cargo encapsulated.

Following step 144, process 140 of method 100 may return to step 143 torepeat centrifugation of the mixture. It is contemplated that steps 143and 144 may be repeatedly performed until the suspension media issubstantially separated from the hydrogel. For example, steps 143 and144 may be repeated until the hydrogel/suspension media clumps aresubstantially broken apart based on a visual inspection through asubstantially transparent container. In some embodiments, steps 143 and144 may be repeated between about 2 times to about 8 times. In someembodiments, steps 143 and 144 may be repeated about 4 times. Followingrepetition of steps 143 and 144, process 140 may proceed to optionalstep 145.

In an optional step 145, more density adjusting material is added to themixture. In an example of optional step 145, additional densityadjusting material is added to the mixture to obtain a ratio of about1:5.5 to increase the size/amount of the middle density adjustingmaterial phase. For example, due to the mechanical agitation in step 144the middle density adjusting material phase may decrease in size/amountdue to some portion of it being displaced into the upper phase.Accordingly, adding an additional layer may aid in a final step ofcentrifugation to pull out any additional suspension media that may beleftover in the hydrogel phase. In some embodiments, the same amount ofdensity adjusting material may be added in optional step 145 as added instep 141.

In a step 146, the mixture is centrifuged for a final time to separatethe suspension media from the hydrogel material. In an example of step146, the mixture is centrifuged at 350 rcf for 3 minutes. In someembodiments, the mixture at step 146 may be centrifuged at a force ofbetween about 200 rcf to about 900 ref. In some embodiments, the mixtureat step 146 may be centrifuged for a period of between about 30 secondsto about 10 minutes.

In a step 147, the hydrogel particles are retrieved from the mixture. Inan example of step 147, the hydrogel particles now void of suspensionmedia, are retrieved from the upper phase. As discussed above, thehydrogel particles in the upper phase will be mostly sequestered fromthe density adjusting material middle phase. Accordingly, the upperphase may be easily retrieved (e.g., by pipetting) and transferred to adifferent container for further processing and/or downstreamapplications. Because the hydrogel particles are less dense than themiddle phase, the hydrogel particles remain on top of the middle phase.Since the hydrogel particles should be protected from air, the cargocompatible aqueous phase of lesser or equal density is on top. Thus, theparticles are sandwiched between the middle phase material and the upperphase solution. To remove the particles, one simply retrieves the upperphase (i.e., hydrogel particles and cargo compatible solution).

Referring now back to FIG. 1 , in a step 150 the hydrogel particles arewashed. In an example of step 150, following retrieval of the hydrogelparticles in the upper phase, the hydrogel particles are placed on afilter and subsequently washed with the proper medium. In someembodiments, the hydrogel particles may be placed on a filter having amesh properly sized to allow for any extra material leftover within thehydrogel mixture to flow through. For example, the mesh filter may havea mesh size of between about 5 μm to about 80 μm. However, it iscontemplated that the size of the mesh filter may be chosen based on thesize of the hydrogel particles generated in step 120. For example, thesize of the mesh filter need be smaller than the hydrogel particles toretain them while other smaller material is allowed to flow through. Itis further contemplated that in some embodiments, the mesh filter may besized to allow for certain sized hydrogel particles to flow throughthereby retaining only hydrogel particles of a certain size. Forexample, a 100 μm mesh filter may be used in step 150 such that anyhydrogel particles having a size smaller than 100 μm may be washedthrough while any hydrogel particles having a size greater than 100 μmmay be retained atop the mesh filter. Such capabilities allow fortargeted retention of specific sized hydrogel particles that may havecertain benefits in downstream applications.

Following placement of the hydrogel particles atop the mesh filter, thehydrogel particles are subsequently washed using a proper media. Forexample, the media may be chosen based on its compatibility with thecargo encapsulated within the hydrogel particles. Similarly, media maybe chosen to not alter the integrity of the hydrogel particles. Examplemedia used in this step may include DMEM, FBS, Penicillin, Streptomycin,PBS, Normal Saline, Lactated Ringers, or any other biocompatible or drugrelevant solution. In some embodiments, the hydrogel particles may bewashed with the media that the hydrogel particles will be stored in forsubsequent applications. In some embodiments, the hydrogel media may bestepwise washed out of the media that was used in the centrifugationsteps (e.g., in step 142) and into a media that will be used insubsequent applications (e.g., a storage solution). For example, somecargo may be sensitive to rapid changes in media. Accordingly, themedia, or contents within the media, may be gradually changed in astepwise manner to lower deleterious effects on the cargo. As an exampleof this, in step 142 the cargo-compatible solution may be PBS; however,following retrieval and washing of the hydrogel particles along with theencapsulated particles, it may be advantageous to have the hydrogelparticles suspended in a different media (e.g., DMEM). To avoid a rapidchange between the two media, multiple wash steps may be performed inwhich PBS is diluted at progressively higher ratios with DMEM until thefinal wash step lacks PBS. For instance, in five wash steps, the firstwash may be PBS, the second wash may be 4 PBS:1 DMEM, the third wash maybe 2 PBS: 1 DMEM, the fourth wash may be 1 PBS: 2 DMEM, and the fifthwash may be DMEM. This example is not to be construed as limiting as anycombination and number of washes may be used depending on theencapsulated cargo and the optimum media for downstream applications.

It is contemplated that washing of the hydrogel particles may beperformed using gravitation based (e.g., drip method), suction based(e.g., vacuum), or low-speed centrifugal based (e.g., at roughly 150 rcffor about 30 seconds) separation methods. These methods may be used toremove the washed liquid and corresponding debris from the mixture. Insome embodiments, there may be one or more wash steps. For example, thehydrogel particles may be washed 1, 2, 3, 4, 5, or more times tosufficiently clear any leftover material from the particles.

In a step 160, the hydrogel particles are resuspended. In an example ofstep 160, the hydrogel particles are resuspended using a sufficientamount of solution and gentle agitation. For example, the hydrogelparticles may be resuspended in a solution that is both cargo-compatibleand suited for downstream applications (e.g., therapeutic use). In someembodiments, the hydrogel particles may be resuspended using pipetting,mechanical perturbance, or another gentle mechanical agitation method toresuspend them in the solution. In some embodiments, the hydrogelparticles may be collected at the bottom of the container so as to storethem for future use. For example, the hydrogel particles in theresuspension media may be centrifuged at a low speed and short period oftime (e.g., about 300 rcf for about 5 minutes) to collect the hydrogelparticles. Alternatively, the resuspended hydrogel particles may beimmediately used for downstream purposes without collection.

As mentioned above, method 100 significantly increases the yield of thehydrogel particles compared to prior art methods. For example, asillustrated in FIG. 4 , prior art methods lacking the suspension mediaremoval steps disclosed herein may have a yield of about 14% that of themethods disclosed herein. In these experiments, 0.15 grams of startinghydrogel material was used. Following separation, prior art methodsyielded 0.064 grams of hydrogel particles while methods disclosed hereinyielded 0.46 grams. The recovery weight includes added mass of waterfrom the swollen hydrogel. Additionally, method 100 may be used togenerate low to high levels of hydrogel particles containingencapsulated cargo. For example, in some embodiments method 100 may beused to generate between about 0.01 mg to about 1 g of hydrogelparticles. In some embodiments, method 100 may be used to generatebetween about 1 g to about 10 g of hydrogel particles. In someembodiments, method 100 may be used to generate between about 10 g toabout 1 kg of hydrogel particles.

As mentioned above, method 100 significantly increases the viability ofthe encapsulated cargo compared to prior methods. For example, asillustrated in FIG. 5 , prior methods of suspension media removal fromthe hydrogel mixture may decrease cargo viability (e.g., cell viability)down to about 25% while methods disclosed herein maintain cargoviability at about 93%. Said another way, of the cargo mixture combinedin step 141, only 25% of that cargo is viable following prior artpurification techniques. Comparatively, methods disclosed herein resultin cargo viability (e.g., cell viability) of about 93%. Error bars shownin FIG. 5 represent standard deviation based on four repetitions ofencapsulating cells via each of the present and prior methods.

Automated Encapsulation of Viable Cells in Hydrogel Particles

FIG. 6 is a block diagram showing an exemplary automated encapsulationmethod 200. An automated method for encapsulating viable cells isdesired to scale-up the process described above, to reduce the chance ofcontamination, and to increase the total number of cells encapsulatedfor use with in vivo applications. In embodiments disclosed herein, theautomated encapsulation method 200 may be used for encapsulating viableequine MSCs in hydrogel particles; however, other types of viablemammalian cells may be encapsulated in hydrogel particles using method200 without departing from the scope hereof.

In a step 210, mammalian cells are grown in a bioreactor. In an exampleof step 210, mammalian cells are grown in a bioreactor (e.g., a ThermoFisher 500L DynaDrive Single-Use Bioreactor) until a desired cell numberis reached. The cells may be harvested between about 10% to 100%confluence. In some embodiments, the cells are harvested between about70% to 80% confluence. Continuous monitoring of cell growth parametersmay be automatically performed via an integrated sensor system.

In a step 220, mammalian cells are harvested automatically from thebioreactor. In an example of step 220, an automated centrifuge systemthat is connected to the bioreactor is used to automatically harvest thecells from the bioreactor. In embodiments, the automated cell harvestprocess follows the same centrifuging procedure as the manual operationdescribed above in step 143 (e.g., spin at 7000 rpm for three minutes).The cells may then be resuspended from a cell pellet in media (e.g.,DMEM, PBS, or other media type), and the centrifuging and resuspendingsteps may be repeated one or more times.

In a step 230, a cell suspension is adjusted to a desired cellconcentration. In an example of step 230, an automated liquid handlingsystem is used to count a sample of cells from a mammalian cellsuspension for determining the cell concentration, and the automatedliquid handling system then adds or removes media to achieve the desiredcell concentration. An example automated liquid handling system is aBeckman Coulter integrated solution, incorporating an automated cellcounting system such as Beckman Coulter Vi-CELL MetaFLEX.

In a step 240, hydrogel materials are combined with the cell suspensionto form a hydrogel mixture. Step 240 is an automated example of step 110described above. For example, an automated liquid handling system isprogrammed to measure and combine components of a cargo-compatiblesolution with a cargo suspension to generate the hydrogel mixture. Thecargo-compatible solution may comprise a hydrogel polymer, a linker, asuspension media, and a surfactant. In embodiments, the cargo-compatiblesolution comprises one or more of PEGNB, DMEM, a linker (e.g. 3.5Kilodalton PEG di-thiol linker), and LAP. In some embodiments, theautomated liquid handling system is programmed to measure and mix thecomponents of the cargo-compatible solution in a dark tube. Thecargo-compatible solution may be prepared ahead of time in batches andstored until required (e.g., at 10° C. for one to seven days).

The cargo suspension comprises the cargo (e.g., cells) and a suspensionmedia that is compatible with the cargo. In embodiments, the cargosuspension comprises the cell suspension from step 230 and thesuspension media comprises an oil such as NOVEC™ 7500 oil (3M™) withfluorosurfactant or other analogous surfactant. The cell suspension andthe suspension media are automatically combined via the liquid handlingsystem.

In a step 245, the hydrogel mixture is mixed. Step 245 is an automatedexample of step 120 described above. In embodiments, the hydrogelmixture is automatically mixed with a shaking device programmed to shakeat a speed of approximately three to five shakes per second and for atotal of between five to seven shakes. In some embodiments, the hydrogelmixture is automatically mixed with a speed of approximately four shakesper second and the hydrogel mixture is automatically mixed for sixshakes. Step 245 is configured to form an emulsion of hydrogel droplets.

In a step 250, the hydrogel mixture is polymerized. Step 250 is anautomated example of step 130 described above. For example, using arobotic arm, the hydrogel mixture may be exposed to a UV light source,or near UV light source at a specific wavelength (e.g., 365-nm to435-nm), a specific energy, and a specific time to cause polymerizationof the hydrogel polymers contained within. In embodiments, tubescontaining hydrogel mixture are transferred to an automated UV exposuredevice using the robotic arm. The automated UV exposure device may beprogrammed to irradiate the hydrogel mixture with UV light (e.g., at 100mW/cm² for 20 seconds). Step 250 is configured to polymerize thehydrogel thereby trapping the cells within the droplets.

In a step 255, a surfactant solution of is prepared. In an example ofstep 255, the automated liquid handling system adds 10 μl of pluronicF68 surfactant to 1 ml media (final concentration of 0.1% F68). Thesurfactant may be added to wash media to help eliminate oil.

In a step 260, a density adjusting material is automatically added tothe hydrogel-suspension media mixture. Step 260 is an example of step141 described above, with the density adjusting material being added viathe automated liquid handling system.

In a step 270, the hydrogel mixture is centrifuged. In an example ofstep 270, the automated liquid handling system adds Opti-prep and mediacontaining surfactant (e.g., 0.1% F68) to the tubes, transfers the tubesto the centrifuge, and the mixture may be centrifuged for 3 minutes at aforce of 350 rcf. Step 270 is an automated example of step 143 describedabove in which a three-phase solution is formed.

In a step 275, the mixture is automatically mechanically agitated. In anexample of step 275, the robotic arm moves the tubes containing thehydrogel mixture to a mechanical mixing device (e.g., a ScientificIndustries GENIE G560 Vortex-Genie 2) and mixes the hydrogel mixtureusing a force of about 1 Newton per 300 μl of particles about 20 timesto dislodge the hydrogel/suspension media clump. Step 275 is an exampleof step 144 described above. For example, hydrogel/suspension mediaclumps are portions of hydrogel particles that are partially heldtogether due to trapped suspension media held therebetween. The trappedsuspension media not only causes the hydrogel particles to stick to oneanother, but the clumps may also stick to the side of the container. Tosufficiently remove the suspension media from the hydrogel particles,the hydrogel/suspension media clumps may need to be dislodged from theside of the container. In some embodiments, a force of between about 0.5Newtons to about 5000 Newtons is used to dislodge thehydrogel/suspension media clumps. In some embodiments, the mechanicalagitation may be performed between about 3 times to about 40 times.Since step 275 is performed after the cargo has been encapsulated in theappropriately sized hydrogel particles, mechanical agitation may be usedat this step without affecting the size of the particles and the amountof cargo encapsulated.

In an optional step 280, more density adjusting material may be added tothe hydrogel mixture. Step 280 is an example of step 145 describedabove. Adding an additional layer of density adjusting material may aidin a final step of centrifugation to pull out any additional suspensionmedia that may be leftover in the hydrogel phase.

In a step 285, the mixture is centrifuged for a final time to separatethe suspension media from the hydrogel material. Step 285 is an exampleof step 146 described above in which the mixture is centrifuged at 350rcf for 3 minutes.

In a step 290, the hydrogel particles are rinsed with media to removeany remaining oil and Opti-prep while avoiding the hydrogels fromdrying. In an example of step 290, the liquid handling system transfersthe hydrogel particles to a filter via automated pipetting and rinsesthe hydrogels with appropriate media (e.g., PBS) via the liquid handlingsystem.

In an optional step 295, the hydrogel particles are examined via anautomated microscope to ensure correct encapsulation and substantiallyno clumping of particles. In an example of step 295, a microscopeequipped with a digital camera captures images of the hydrogel particlesand a sample of the particles are evaluated automatically via digitalimaging software trained to determine correct encapsulation andsubstantially no clumping of particles. In embodiments, correctencapsulation comprises a mean particle size distribution within aboutone standard deviation from a desired diameter, and particles aredistributed within a 10% error of training images demonstrating noclumping.

In a step 300, the hydrogel particles are retrieved and transferred fordispensing. In an example of step 300, the hydrogel particles areretrieved via the automated liquid handling system and transferred to adispensing reservoir operably connected to an automated filling system.The automated filling system may be an Integrated Automated FillingMachine from the Filamatic Company, in some embodiments.

In a step 310, the automated filling system dispenses a predeterminedamount of hydrogel particles into cryo-vials. In an example of step 310,hydrogel particles are dispensed in 1-mL aliquots into cryo-vials.

In a step 320, a cryoprotectant is added to each cryo-vial. In anexample of step 320, 0.2-mL of proprietary Cryoprotectant is added viathe automated liquid handling system to each of the cryo-vials. Thisstep helps protect the encapsulated cells from damage during freezingfor long-term storage.

In a step 330, a robotic arm is used to transfer the cryo-vials to acontrolled-rate freezing device for cooling the encapsulated cells. Inan example of step 330, the encapsulated cells are cooled at apredetermined rate via the controlled-rate freezing device (e.g., aCytiva VIA Freeze Controlled-Rate Freezer) to freeze the hydrogelparticles for storage.

In a step 340, cooled vials of encapsulated cells are transferred to acryogenic storage system. In an example of step 340, cooled vials ofencapsulated cells are transferred via the robotic arm to a cryogenicfreezer (e.g., at −196° C.). In some embodiments, the cryogenic storagesystem is equipped with automated inventory tracking, which logs thedetails (e.g., contents, date, etc.) for facilitating later retrieval.

Although the invention has been described with reference to theembodiments illustrated in the attached drawing figures, it is notedthat equivalents may be employed and substitutions made herein withoutdeparting from the scope of the invention as recited in the claims.

Having thus described various embodiments of the invention, what isclaimed as new and desired to be protected by Letters Patent includesthe following:

1. A hydrogel particle encapsulation and suspension media removalmethod, comprising: combining hydrogel materials, the hydrogel materialscomprising a hydrogel polymer, a linker, a cargo suspension, and asuspension media; mixing the hydrogel materials to form ahydrogel-suspension media mixture; polymerizing the hydrogel materialsto form hydrogel particles having encapsulated cargo; and substantiallyremoving the suspension media from the hydrogel-suspension mediamixture, comprising: adding a density adjusting material; forming athree-phase solution, wherein the three-phase solution comprises thedensity adjusting material settled between the hydrogel particles andthe suspension media; centrifuging the three-phase solution; agitatingthe three-phase solution; and retrieving the hydrogel particles lackingthe suspension media.
 2. The method of claim 1, wherein mixing thehydrogel materials comprises: 1) accelerating a container holding thehydrogel materials in a first direction, 2) decelerating the containerto a stop, 3) accelerating the container in a second direction oppositethe first direction back to an initial position, and 4) repeating steps1-3 a plurality of times.
 3. The method of claim 1, wherein forming thethree-phase solution comprises centrifuging the hydrogel-suspensionmedia mixture after adding the density adjusting material to provide aforced separation between the suspension media, the density adjustingmaterial, and the hydrogel particles.
 4. The method of claim 1,comprising adding a cargo-compatible solution following the step ofadding a density adjusting material, wherein the cargo-compatiblesolution comprises a cargo-compatible surfactant.
 5. The method of claim1, following the step of substantially removing the suspension media,washing the hydrogel particles on a filter and resuspending the hydrogelparticles in a storage solution.
 6. The method of claim 5, comprisingresuspending the hydrogel particles in a mixture of suspension media andstorage solution, and repeating the steps of washing the hydrogelparticles and resuspending the hydrogel particles in a mixture ofsuspension media and storage solution having progressively higher ratiosof storage solution to gradually resuspend the hydrogel particles in thestorage solution in a stepwise manner.
 7. The method of claim 1,comprising repeating the steps of agitating the three-phase solution andcentrifuging the three-phase solution a plurality of times.
 8. Themethod of claim 7, wherein combining hydrogel materials comprises addingthe hydrogel materials to a substantially transparent container suchthat the steps of agitating the three-phase solution and centrifugingthe three-phase solution a plurality of times are repeated untilhydrogel/suspension media clumps are substantially broken apart based ona visual inspection through the substantially transparent container. 9.The method of claim 7, comprising adding additional density adjustingmaterial following the steps of agitating the three-phase solution andcentrifuging the three-phase solution a plurality of times, andcentrifuging the three-phase solution a final time.
 10. The method ofclaim 1, wherein agitating the three-phase solution comprisesmechanically agitating the three-phase solution.
 11. The method of claim1, wherein a density of the density adjusting material is from 1.2 g/mLto 1.4 g/mL.
 12. The method of claim 1, wherein the density adjustingmaterial comprises one or more surfactants that are added to improve theremoval of suspension media.
 13. The method of claim 1, wherein thedensity adjusting material comprises any one or a combination ofoptiprep or iodixanol.
 14. The method of claim 1, wherein centrifugingthe three-phase solution comprises centrifuging at 7000 RPM for 3minutes.
 15. The method of claim 1, wherein the three-phase solutioncomprises an upper phase, a middle phase, and a lower phase, the upperphase comprising the hydrogel particles suspended within acargo-compatible solution, the middle phase comprising the densityadjusting material, and the lower phase comprising the suspension media,and the step of retrieving the hydrogel particles lacking the suspensionmedia comprises collecting the upper phase.
 16. A method for generatingand purifying hydrogel particles comprising encapsulated cargo, themethod comprising: combining hydrogel materials in a container, thehydrogel materials comprising a hydrogel polymer, a linker, a cargosuspension, and a suspension media; mixing the hydrogel materials toform a hydrogel-suspension media mixture, wherein mixing comprisesshaking the container until the hydrogel materials are substantiallymixed; polymerizing the hydrogel materials to form hydrogel particleshaving encapsulated cargo; and substantially removing the suspensionmedia from the hydrogel-suspension media mixture, comprising: adding adensity adjusting material; adding cargo-compatible solution wherein thecargo-compatible solution includes a cargo-compatible surfactant;centrifuging the hydrogel-suspension media mixture with the densityadjusting material and cargo-compatible solution to form a three-phasesolution comprising: 1) an upper phase comprising the hydrogel particlessuspended within the cargo-compatible solution, 2) a middle phasecomprising the density adjusting material, and 3) a lower phasecomprising the suspension media; agitating the three-phase solution viamechanical agitation; centrifuging the three-phase solution; andretrieving the hydrogel particles lacking the suspension media bycollecting the upper phase.
 17. The method of claim 16, comprisingrepeating the steps of adding density adjusting material, agitating thethree-phase solution, and centrifuging the three-phase solution.
 18. Themethod of claim 16, wherein a density of the density adjusting materialis about 1.3 g/mL.
 19. The method of claim 16, wherein the upper phaseonce collected comprises a yield of between 0.1 gram and 1 gram ofhydrogel particles.
 20. The method of claim 16, wherein the cargosuspension comprises viable cells and the upper phase once collectedcomprises cell viability of about 93%.
 21. A hydrogel particleencapsulation and suspension media removal method, comprising: combininghydrogel materials in a vial via an automated liquid handling system,the hydrogel materials comprising a hydrogel polymer, a linker, a cargosuspension, and a suspension media; transferring the vial to a shakingdevice via a robotic arm; mixing the hydrogel materials via the shakingdevice to form a hydrogel-suspension media mixture; transferring thevial from the shaking device to a UV light source via a robotic arm;polymerizing the hydrogel materials via the UV light source to formhydrogel particles having encapsulated cargo; and substantially removingthe suspension media from the hydrogel-suspension media mixture via therobotic arm and the automated liquid handling system, comprising: addinga density adjusting material to the vial; adding a cargo-compatiblesolution to the vial, wherein the cargo-compatible solution comprises acargo-compatible surfactant; centrifuging the vial; forming athree-phase solution, wherein the three-phase solution comprises thedensity adjusting material settled between the suspension media andcargo-compatible solution containing the hydrogel particles; agitatingthe three-phase solution via an automated mechanical mixing device;centrifuging the vial; and retrieving the hydrogel particles lacking thesuspension media.
 22. The method of claim 21, wherein mixing thehydrogel materials comprises: 1) accelerating the vial in a firstdirection, 2) decelerating the vial to a stop, 3) accelerating the vialin a second direction opposite the first direction back to an initialposition, and 4) repeating steps 1-3 a plurality of times.
 23. Themethod of claim 22, wherein the steps of mixing the hydrogel materialsare repeated six times.
 24. The method of claim 21, comprising preparingthe cargo suspension prior to mixing the hydrogel materials, comprisingthe steps of: growing mammalian cells in a bioreactor until a desiredcell number is reached; harvesting the mammalian cells from thebioreactor via an automated centrifuge system; and adjusting a cellconcentration of the mammalian cells to a desired cell concentration viathe automated liquid handling system.
 25. The method of claim 21,comprising washing the hydrogel mixture via the liquid handling system.26. The method of claim 21, comprising examining hydrogel particles fromthe hydrogel mixture via an automated microscope to ensure correctencapsulation and substantially no clumping of particles.